Method of cutting target members using a cutting saw device

ABSTRACT

A diamond wire saw and method provides a frame that includes a clamp that attaches to a target (e.g. piling, beam, tubular), an elongated toothed rack extending away from the mount and target, and a moving portion that carries the diamond wire and motor drives that advance the moving portion toward the target and along the toothed rack while driving the wire around roller guides.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation of U.S. patent application Ser. No. 13/920,447Jun. 18, 2013 (issued as U.S. Pat. No. 9,145,749 on Sep. 29, 2015),which is a continuation of U.S. patent application Ser. No. 13/367,492,filed Feb. 7, 2012 (issued as U.S. Pat. No. 8,465,227 on Jun. 18, 2013),which was a continuation of U.S. patent application Ser. No. 13/084,726,filed Apr. 12, 2011 (issued as U.S. Pat. No. 8,109,693 on Feb. 7, 2012),which was a continuation of U.S. patent application Ser. No. 12/142,893,filed Jun. 20, 2008, (issued as U.S. Pat. No. 7,922,424 on Apr. 12,2011), which applications are incorporated herein by reference. Priorityof these applications is hereby claimed.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable

REFERENCE TO A “MICROFICHE APPENDIX”

Not applicable

BACKGROUND

The present invention relates to the removal of targets (e.g. underwatertubular members) as a part of oil well intervention and decommissioning.More particularly, the present invention relates to a method andapparatus of cutting of targets above and below the water line such astubular members associated with oil and gas well drilling platforms andproduction platforms. Even more particularly, the present inventionrelates to an underwater cutting method that provides cold-cutting oftargets, tubular members, or “tubulars” using a specially configureddiamond wire saw arrangement.

The following patents are directed to diamond wire saws and continuouswire saws as well as methods of cutting structures underwater.

SUMMARY

In one embodiment is provided an underwater cutting apparatus and methodof compact size, lightweight and simple design.

In one embodiment is provided a cold-cutting saw device that employs tworemotely controlled motors, preferably hydraulic motors mounted to aframe such as a lightweight aluminum frame.

In one embodiment one of the hydraulic motors propels or circulates acontinuous loop of diamond wire (for example, ⅝ inches outer diameter)that is wound about a series of alignment wheels or sheaves. In oneembodiment the cutting diamond wire can travel at a rate of betweenabout 20 and 25 feet per second as an example.

In one embodiment is provided a second motor drive moves a pinion gearof a rack and pinion mechanism. This rack and pinion mechanism moves apart of the frame along a feed shaft (for example, composite or steel).The movement of part of the frame pushes or pulls the circulatingdiamond wire into and through the target material or tubular as it iscut.

In one embodiment the feed shaft can contain the teeth of the rack, andthe feed shaft can support the weight of the saw frame. The feed shaftcan also stabilize the cutting wire, maintaining the cutting wire in aconstant plane that is generally normal to a mounting clamp and thematerial being cut.

In one embodiment a mounting clamp can be used to secure the entire sawassembly to the target or tubular or other material being cut utilizinga chain and binder or hydraulic clamping system.

In one embodiment the saw device can be used underwater, above water,and/or in dangerous to human environments, such as in nuclear reactors.

In one embodiment the saw device can be used to cut various combinationsof solid and tubular dissimilar steels, synthetic composite materials,or dissimilar aggregates (concrete).

In one embodiment the saw device can be used to cut different sizematerials ranging from about two inches to about ninety-six inches indiameter as the target.

One embodiment includes a single, centralized feed shaft controllablyslidable over a rack and pinion feeds mechanism which controls the feedand/or retraction amount/rate of the cutting diamond wire.

One embodiment includes a centralized feed shaft which has twolongitudinal arms each longitudinal arm having a feed shaft controllablyslidable over a rack and pinion feeds mechanism which controls the feedand/or retraction amount/rate of the cutting diamond wire. In thisembodiment two feed motors and gears can be used to control feed and/orretraction of the cutting wire.

One embodiment includes a rectangular or square feed shaft forstabilizing the saw and maintaining the cutting wire perpendicular to apositioning clamp during cutting movements of the cutting wire.

In one embodiment the cutting saw frame is generally U-shaped allowingboth a pushing type cut for the cutting wire and a pulling type cut forthe cutting wire.

In one embodiment a plurality of alignment wheels or sheaves arearranged symmetrically on the saw frame to provide uniform tension tothe cutting wire during operation.

In one embodiment one or more of the alignment wheels or sheaves havemotion indicating indicia depicting movement of the cutting wire. In oneembodiment one or more of the alignment wheels or sheaves have arotating surface which includes a plurality of indicia markings. In oneembodiment one or more of the alignment wheels or sheaves include asurface which is of two colors. In one embodiment one or more of thealignment wheels or sheaves are about 50 percent one color and 50percent another color. The cutting indicia on the one or more alignmentwheels or sheaves as they spin provides a visual indicator of when thecutting wire is in motion. In one embodiment the speed of rotation ofthe indicia on the alignment wheels or sheaves provides a visualindicator of the relative speed of the cutting wire.

In one embodiment the saw device can include a wire tensioning systemwhich has an axial feed for the tension system. In one embodiment theaxial feed tensioning system can be manually operated.

In one embodiment the cutting saw can include a cutting coolant systemfor providing lubricating and/or cooling liquids on the wire duringcutting operations. In one embodiment the cooling system can include oneor more spray nozzles.

In one embodiment the saw device can include a platform design for sawsizes to cut materials from 2″ OD and greater. In one embodiment the sawdevice can be sized from a 26″ cutting area to a 100″ cutting area. Inone embodiment a single man portable version of the saw device can beprovided having a relatively small opening (such as 14 inches) forsingle man operations (e.g., where one man can easily lift and positionthe cutting while above water).

In one embodiment the saw device can be mounted on the target andclamped in place using a remote operated vehicle (“ROV”) and the sawdevice being controlled remotely from the surface, or the saw can beoperated independently utilizing the hydraulic system integrated intomany ROV systems with its full control under the command of the ROVoperator. In this embodiment the cutting saw can include a remoteoperated clamping system (such as a hydraulic clamp). The ROV will havethe cutting saw with the remote operated clamping system attached to theROV, and the ROV will position the cutting saw at the place of cut onthe target, and the clamping system will be activated remotely causingthe saw to attach to the target, and the cutting saw will be remotelyactivated causing the cutting wire to spin. The cutting wire will beremotely moved forward by the topside operator and the cut made similarto operations under other embodiments. However, the ROV will remainattached to the cutting saw during and after the cut is made. After thecut is made the ROV can bring the cutting saw to the surface or canbring the cutting saw to the next target to be cut.

In one embodiment the saw device can include a bulkhead for theplacement of “hot stab” hydraulic connections for use with ROV systems.

In one embodiment the saw device can include a flotation system. In oneembodiment this floatation system can be one or more modules ofsyntactic foam. In one embodiment the floatation system provides aboutneutral buoyancy to the saw device. In one embodiment the floatationmodules can be attached to the saw and/or mounted inside void spaces ofthe saw. In one embodiment buoyancy modules are used in combination withROV operations. In one embodiment buoyancy modules are used to assistdiver handling, positioning, and placement of the saw device.

In one embodiment lifting sling attach points allow the use of quickrelease shackles to speed diver and/or ROV manipulation during sawdevice mounting to the target material.

In one embodiment the cutting saw apparatus can include an emergencyshutoff system. In one embodiment a remotely operated emergency shutoffsystem can be connected to the cutting saw. In one embodiment the remoteshutoff can be remote from an operator's shutoff for the cutting saw. Inone embodiment this remote shutoff can be under the control of a DiveSupervisor or Customer Representative.

In one embodiment the saw device can be mounted to the target pieceeither manually such as with a manual clamp (e.g., a chain andcome-along). In one embodiment the saw device can be mounted to thetarget piece using a hydraulic clamping system.

In one embodiment the saw device can include a mounting bracket for oneor more underwater lights along with one or more cameras for visualmonitoring at the surface. In one embodiment cutting operations can bevisually recorded on the surface using a video monitoring system such asa video camera. In one embodiment a fiber optic cable can be used totransmit the video signal from the camera to the surface.

In one embodiment the operator of the saw device can be above water andthe saw device be below water. In one embodiment the operator can usethe resistance on the cutting wire to determine when to advance thecutting wire of the saw device. In one embodiment the resistance on thecutting wire can be relatively determined based on the back pressure(e.g., hydraulic back pressure) to the driving motor for the cuttingwire. In one embodiment the cutting process includes the step ofadvancing the cutting wire a short distance, and watching the resistanceon the cutting wire increase and then over time decrease (as the cut onthe target is made), and after noting the decrease in wire resistance,again advancing the cutting wire and watching the resistance on thecutting wire again increase. In one embodiment these two steps ofadvancing the cutting wire a short distance, and watching the resistanceon the cutting wire first increase and then decrease before againadvancing the cutting wire are repeated a plurality of times until thecut is made through the target.

In one embodiment the operator of the saw device can advance the cuttingwire until a specified resistance is seen on the cutting wire. At thispoint the operator can decrease the feed rate until the resistance onthe cutting wire decreases. Upon decrease of the resistance to thecutting wire the operator can again increase the feed rate of thecutting wire. This feed rate adjusting process can be repeated until thecut is completed.

In one embodiment one or more of the alignment wheels or sheaves can bereplaced while the saw device is underwater, such as during the middleof a cut and without moving the saw device above water.

In one embodiment the wire can be replaced while the saw device isunderwater, such as during the middle of a cut and without moving thesaw device above water.

In one embodiment while underwater after a first cutting wire has brokena second cutting wire can be placed on the saw device and properlytensioning without having to first return the saw device to the surface.In one embodiment the axial feed wire tensioning system can be used toproperly tension the cutting wire while the saw device remainsunderwater.

In one embodiment the method includes the steps of:

(a) starting a cut with a pushing (or pulling) type cut;

(b) before the cut is completed, stopping the cutting wire and at leastpartially removing the cutting wire from the alignment wheels orsheaves;

(c) moving the saw device into a different pulling (or pushing) type cutposition but without bringing the cutting saw above;

(d) placing cutting wire on the alignment wheels or sheaves; and

(e) completing the remaining portion of the cut in the other type ofcutting mode.

In one embodiment step “c” is completed without repositioning the clampholding the cutting saw on the target.

In one embodiment step “c” is performed by moving the cutting frame to asubstantially extended position. In one embodiment the cutting frame ismoved to a completely extended position.

In one embodiment step “c” is performed by moving the cutting frame to asubstantially retracted position. In one embodiment the cutting frame ismoved to a completely retracted position.

In one embodiment the same cutting wire is used during steps “a” and“e.”

In one embodiment a different cutting wire is in step “e” as that usedin step “a”.

In one embodiment the cutting wire used in step “a” is a loop which isbroken into a wire string with two ends and during step “d” the two endsare reconnected to form a loop.

In one embodiment the cutting wire used in step “a” remains in a loopand is placed around the target being cut before step “d”.

In one embodiment the tensioning mechanism is used to loosen the cuttingwire in step “b.”

In one embodiment the tensioning mechanism is used to tension thecutting wire in step “d.”

In one embodiment the method includes the steps of:

(a) starting a cut with a pushing (or pulling) type cut;

(b) before the cut is completed, the first cutting wire breaking;

(c) removing the first cutting wire from the alignment wheels orsheaves;

(d) without bringing the cutting saw above water installing a secondcutting wire on the alignment wheels or sheaves;

(e) adjusting the wire tension on the second cutting wire; and

(f) completing the remaining portion of the cut with the second cuttingwire.

In one embodiment the tensioning mechanism is used to loosen the firstcutting wire in step “c.”

In one embodiment the tensioning mechanism is used to tension the secondcutting wire in step “d.”

In one embodiment the method includes the step of vertically adjustingat least one of the alignment wheels or sheaves while the cutting sawremains underwater.

In one embodiment when cutting a target (such as multiple strings ofungrouted casing) where binding of the cutting wire can occur aftercutting just over one-half of the way through the target. The cuttingwire can be moved to the outside of the target, and without changing theclamp position, complete the cut by pulling the diamond wire through theremaining cut zone of the target material.

In one embodiment the cold-cutting saw device of the present inventioncan be used in a subsea environment and top side. The cutting saw of thepresent invention can be remotely operated. The remote operation can bemonitored via saw mounted camera or cameras. The present invention canbe adapted for use with remotely operated vehicles or ROV's.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

For a further understanding of the nature, objects, and advantages ofthe present invention, reference should be had to the following detaileddescription, read in conjunction with the following drawings, whereinlike reference numerals denote like elements and wherein:

FIG. 1 is a perspective view of one embodiment of the apparatus;

FIG. 2 is side elevation view showing the cutting saw of FIG. 1 attachedto a target before making a cut;

FIG. 3 is another elevation view showing the cutting saw of FIG. 1 aftermaking a cut and the target being lifted by a vessels crane;

FIG. 4 is a top view of the cutting saw of FIG. 1 attached to a cuttingtarget where the frame is completely retracted;

FIG. 5 is a top view of the cutting saw of FIG. 1 attached to a cuttingtarget where the frame is partially extended but before starting a cuton the cutting target;

FIG. 6 is a top view of the cutting saw of FIG. 1 attached to a cuttingtarget where the frame is partially extended making a cut on the cuttingtarget;

FIG. 7 is a top view of the cutting saw of FIG. 1 attached to a cuttingtarget where the frame is fully extended and has completed the cut onthe cutting target (and in the position shown in FIG. 3);

FIG. 8 is a rear view of the cutting saw of FIG. 1;

FIG. 9 is a fragmentary plan view of the cutting saw of FIG. 1 showingthe tensioning apparatus;

FIG. 10 is a fragmentary view taken along lines 10-10 of FIG. 9;

FIG. 11 is a fragmentary view taken along lines 11-11 of FIG. 9;

FIG. 12 is a fragmentary elevation view of the cutting saw of FIG. 1showing a positionally controllable video camera mounted on the cuttingsaw (with the option of adding a light);

FIG. 13 is a plan view of the cutting saw of FIG. 1 during cutting andillustrating the cooling system;

FIG. 14 is a fragmentary perspective view illustrating the installationof an alignment wheel or sheave and schematically indicating itsinstallation and/or vertical adjustment;

FIG. 15 is a front perspective view of an alternate hydraulic clampingarrangement;

FIG. 16 is a rear perspective view of the hydraulic clamp of FIG. 15;

FIG. 17 is a plan view of the cutting saw of FIG. 1 showing floatationmodules installed;

FIG. 18 is a side view of the cutting saw of FIG. 17;

FIG. 19 is a partial perspective view showing a cutting saw operator ata control panel and video monitor;

FIG. 20 is a fragmentary view of one type of diamond cutting wire;

FIG. 21 is a perspective view of the cutting wire of FIG. 20;

FIG. 22 is a perspective view showing diver adjusting the tensioner andtension on the cutting wire; and

FIG. 23 is a perspective view showing diver replacement of cutting wireand a guide roller.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1-23 show the preferred embodiment of the apparatus of the presentinvention, designated generally by the numeral 10. Cutting apparatus 10can be used to cut a target 11 which can be a tubular, piling, steelbeam, or other underwater structure that is to be cut. Often, suchtargets 11 are cut as part of oil well intervention and decommissioningactivities. In a preferred embodiment, the apparatus 10 of the presentinvention can be used in a subsea environment for subsea cutting oftarget 11 at or near the seabed 12, or below the seabed 12 after an areaaround the target has been excavated to provide room for the cutting sawto operate. If an area around the target has been excavated a retainingwall or cofferdam can be used to resist filling of the opened spacearound the target.

Cutting apparatus 10 can be employed to cut a target for above watercutting when fitted with optional cooling system (FIG. 13). Cuttingapparatus 10 employs a frame 13. The frame 13 can be supported withrigging such as shackles 14 and lift cables 15. In FIGS. 1 and 2, frame13 is attached to target 11 using mounting clamp 17. The mounting clamp17 can be attached to the target 11 using cable/chain attachments 18,19, or a hydraulic clamp (see FIGS. 15-16).

A feed shaft 20 extends from mounting clamp 17 as shown in FIG. 1. Themounting clamp 17 can provide a receiver 22 that enables attachment offeed shaft 20 to mounting clamp 17 using a pin connection (with a quickrelease snap ring), bolted connection, or other connection. Feed shaft20 is an elongated linear member having a toothed rack 21.

Frame 13 includes mounting clamp 17, feed shaft 20 and moving portion orsection 23. Moving portion 23 includes transverse section 60 and arms24, 25 which are spaced apart. Arms 24, 25 can be generally parallel. Anopen end 26 is provided to moving portion 23 in between arms 24, 25generally opposite drive roller 31. Moving portion 23 provides sleeve 61at transverse section 60. Sleeve 61 is receptive of feed shaft 20 andforms a sliding connection therewith.

A plurality of sheaves or roller guides 27-30 are mounted to movingportion 23. A tensioner 32 is mounted to moving portion 23 and includesroller guide 74. An endless diamond wire 16 is wound about the rollerguides/sheaves 27-30, drive roller 31 and tensioner 32 roller guide 74as shown. Larger diameter roller 31 is a drive roller 31 drives diamondwire 16 clockwise when viewed in plan (see FIG. 6), as indicatedschematically by arrows 50. Rollers 27-30 can rotate in the directionsillustrated by arrows 59 in FIGS. 6-7 (rotation in the oppositedirections is also available). Arrow 57 shows the direction of rotationof drive roller 31. Arrow 58 in FIG. 6 shows the direction of travel ofmoving portion 23 in relation to feed shaft 20. Arrow 56 shows thedirection of rotation of roller 74 of tensioner 32.

Rollers 27-30 can be painted or marked to divide each roller 27-30 intosemi-circular areas 51-52 of different color and thus easily showrotational movement during operation, such as when viewed with a remote,underwater camera 81. Each roller 27-30 is removable from moving section23 for ease of replacement. Each roller 27-30 rotates upon a verticalshaft 53, which rotation can be facility by one or more bearings such astwo sets of 3 centimeter stainless steel sealed bearings. Each shaft 53is held in vertical tube 54 with one or more set screws 55. Set screws55 enable replacement of a selected roller 27-30 and its shaft 53 aswell as vertical adjustment (see arrows 62, FIG. 8) by loosening setscrews 55. Set screws 55 can be tightened when a selected roller 27-30and shaft 53 is located at the proper vertical elevation.

Support vessel 35 at water surface 36 can provide a crane 37 that liftsand lowers cable 15 and any needed rigging (e.g. slings). Hydraulicfluid supply lines 33 are provided for supplying hydraulic fluid fromsupport vessel 35 and hydraulic control unit 34 to hydraulic motordrives 40, 44.

The apparatus 10 of the present invention can be remotely operatedunderwater from a vessel 35. Support vessel 35 can provide a hydrauliccontrol unit 34 that enables remote operation of cutting apparatus 10.Arrow 38 in FIG. 3 illustrates the lifting of a section of structure ortubular or target 11 after it has been cut using cutting apparatus 10 atcut 39.

A pair of motor drives 40-44 are each provided with hydraulic flowlines. These hydraulic flow lines are a part of the hydraulic fluidsupply 33. The motor drive 40 is provided with hydraulic lines 41, 42.The motor drive 44 is provided with hydraulic lines 45, 46. Motor drive44 powers drive roller 31. Motor drive 40 powers pinion gear 49. Themotor drive 40 powers smaller gear 47 which powers larger gear 48 usingbelt drive 43. Pinion 49 is attached to larger gear 48 and rotatestherewith. The pinion 49 engages toothed rack 21 of feed shaft 20.

FIGS. 9-11 show the tensioning mechanism 32 in more detail. Thetensioning mechanism 32 employs a t-shaped beam that includes web 63 andflange 64. End plate 65 is attached to web 63 flange 64 as shown in FIG.11. A threaded rod 68 is mounted to end plate 65 at opening 67. Threadedrod 68 also attaches to nut 69 at internally threaded opening 70.Adjustment head 66 attaches to and rotates with threaded rod 68. Arotation of rod 68 using adjustment head 66 in the direction of arrows73 in FIG. 11 effects a sliding movement of bearing/slide 71 asillustrated by arrows 72 and 72′ in FIG. 11. This adjustment ofadjustment head 66 to effect a movement of slide 71 changes the positionof tensioner 32 roller 74 as shown in FIG. 9. By moving the roller 74 inFIG. 9 from the position shown in hard lines to the position shown inphantom lines, tension can be applied to diamond wire 16 as indicated byarrow 77 in FIG. 9. Roller 74 provides an annular groove 75 that isreceptive of diamond wire 16 as shown in FIGS. 10 and 11. An annularflange or stop 76 can be provided at the end portion of threaded rod 68opposite adjustment head 66 for limiting the travel of slide/bearing 71away from end plate 65. A flange 66′ (e.g., washer) can be welded on rod68 to limit movement of rod 68 in the direction of arrow 72′.

FIG. 12 shows camera mount 80 for supporting a video camera 81 and light92. The video camera 81 enables an operator at a remote location such asa hydraulic control panel to view cutting operations when conductedunderwater. Camera mount 80 includes a post 82 that can be l-shaped asshown in FIG. 12. Post 82 can be mounted in tube 83 and secured with setscrews 78. Camera 81 and light 92 can be remotely operated using cable79 or other known instrumentation and can be adjusted rotationally inthe direction of arrow 93 (or the opposite direction of arrow 93), andalso adjusted vertically in the directions of arrows 94 and 95. Camera81 can provide a video signal for monitor 117 which is being viewed byoperator 116 (FIG. 19).

FIG. 13 shows an optional cooling system 84. Cooling system 84 employs aheader or flow line 85 fitted with one or more nozzles 86. Each nozzle86 is capable of directing a water jet 87 to the area being cut as shownin FIG. 13. Water supply conduit 88 can be used to transmit water toheader or flow line 85. Water supply conduit 88 attaches to header/flowline 85 at tee fitting 89. Arrow 90 in FIG. 13 illustrates the inflow ofwater to the cooling system 84 via water supply conduit 88, tee fitting89 and flow line/header 85. Other cooling fluids beside water can beused such as liquid nitrogen.

FIGS. 15 and 16 show an optional hydraulic clamp, designated by thenumeral 100. Clamp 100 provides a receiver 101 that is receptive of feedshaft 20. Receiver 101 can provide one or more openings 102 that enablea bolted connection to be made between receiver 101 and feed shaft 20.Hydraulic clamp 100 provides a body 103 with a hinge 104 that pivotallyattaches arm 105 to body 103. Cylinder 106 can be supported at one endon body 103 with a pinned connection 112, the other end of cylinder 106provides a pushrod 107 that connects to pivoting arm 105 at pinnedconnection 108. Arrows 109 in FIGS. 15 and 16 illustrate a pivotingmovement of arm 105 relative to body 103.

FIGS. 17 and 18 illustrate floatation material 110 that can be bolted tomoving portion 23 using bolted connections 111 for example. Thefloatation material 110 can be any buoyant material such as styrofoam.Floatation material 110 is preferably comprised of a plurality offloatation modules which are detachably connectable to cutting saw 10such as through bolted connections 111. In one embodiment a kit of aplurality of different sizes of floatation modules can be included toadjust the amount of buoyant force on cutting saw 10.

FIG. 19 illustrates a control panel 113. Control panel 113 can belocated on the deck or cabin of vessel 35. Control panel 113 providesinstruments 114 and control valves 115 that enable an operator 116 tocontrol operation of the cutting apparatus 10. A monitor 117communicates with camera 81 for enabling the operator 116 to viewcutting operations as well as the overall apparatus 10.

FIGS. 20 and 21 show diamond wire 16 in more detail. The diamond wire 16can provide an elongated wire rope body 121 with spaced apart annularabrasive members 122 mounted thereon as shown in FIGS. 20 and 21. In analternative embodiment the cutting wire 16 can be a continuous diamondimpregnated wire system. Both of these types of cutting wire 16 areconventionally available.

FIGS. 22 and 23 show adjustment of the tensioner mechanism 32 (FIG. 22)and removal or replacement of a wire 16 and/or of a roller 29. In FIG.22, a diver 118 uses a wrench 119 to adjust adjustment head 66 oftensioner mechanism 32 and adjust the tension on cutting wire 16. InFIG. 23 diver 118 is shown installing a new wire 16′ to replace originalcutting wire 16 which may have broken during cutting operations (whichreplacement step is being done completely underwater). In FIG. 23, diver118 is shown removing roller guide 29 from tube 54 so that it can bereplaced with a spare roller guide 29′ that is shown in FIG. 23 attachedto a lift line 120 (which replacement step is being done completelyunderwater).

Typical Method of Subsea Operation

The following includes steps in one embodiment for operating the cuttingsaw in a subsea environment:

1. Job to be performed can be discussed at length with customer. Detailsof the job can include tooling placement on vessel 35, shipboard powerrequirements, water depth, casing sizes to be cut, offshore location,departure dock and safety orientation.

2. Cutting saw 10 and support equipment is prepared and function testedprior to transport to job site.

3. Cutting saw 10 and support equipment is transported to job site suchas through customer's supply vessel 35 and to the work location thatcould be a platform, drilling rig, drill ship, work barge, dive boat, orlift boat.

4. Cutting saw 10 and support equipment is offloaded via work platformcrane 37 and placed on the deck in accordance with vessel Captain, toolpusher, and/or Customer representative's instructions.

5. Cutting saw 10 hydraulic control 113 is connected to hydraulic powersupply unit.

6. Hoses are used to connect control panel 113 and cutting saw 10 viaeither a single, 4-hose, umbilical hose bundle or two 2-hose umbilicalhose bundles. All umbilical hoses are stored on powered reels for easeof transport, unspooling, and reclaiming hoses from the sea floor.

7. 1″ hose is connected to the main drive wheel motor 40 of the cuttingsaw 10 and ½″ (or ¾″) hose connected to drive motor for cutting saw'saxial feed system (rack and pinion system 20/21).

8. Loop of cutting wire 16 is placed around the alignment wheels orsheaves (10″ idler pulley wheels 27-30 and the 24″ main wire drive wheel31). In one embodiment alignment wheels or sheaves 27-30 are painted tobe ½ black to allow their rotation to be viewed underwater via a sawmounted camera. When viewing of the rotating wheels substantiallyappears solid, the wheel speed, and cutting wire 16 speed can beconsidered adequate for cutting.

9. The tension of the cutting wire loop 16 is applied via the axialtension arm 32 using a wrench (FIG. 9). This adjustment is easily madein a subsea environment should cutting wire replacement be necessary.The cutting saw 10 need not be brought to the surface for changing thecutting wire or for adjusting wire tension.

10. Operators start the hydraulic power unit, adjust appropriate outputpressure and gallons per minute flow rate and test the cutting saw 10operation while the cutting saw 10 is above water (e.g., on the surfaceof the deck of the ship 35).

11. Once test is deemed good, diver support crews attach sonarpositioning beacons, observation camera 81 and light, visualillumination/indication (cylalume glow sticks) and any necessary handtools for wire changes sub-sea.

12. Deck rigging crews connect the furnished three part sling to the bigor small block of the vessel crane 37.

13. Once a diver is in the water and at depth, the vessel crane 37lowers the cutting saw 10 to the depth and location of the target 11 tobe cut. Air bags and/or foam floatation modules 110 can be attached oradded to the cutting saw 10 to approximate a neutral buoyancy conditionfor the cutting saw 10, and to increase the diver's ability tomanipulate the cutting saw 10.

14. Diver manually manipulates cutting saw 10 to the desired cut area ontarget to be cut and provides directions (e.g., oral or verbal such asthrough a transmitter) to the crane operator to assist in verticallypositioning the cutting saw 10 as needed.

15. Once the desired cut position is reached, the diver secures (clamp17) the cutting saw 10 to the target to be cut (e.g., using manual chainbinders or come-along or a hydraulically operated clamp 100 can be usedin place of the manual chain binder assembly 17.

16. Once the cutting saw 10 is mounted, the diver removes all attachedslings, tooling and handling ropes. The diver ensures that any umbilicaland hydraulic lines are clear of all mechanical moving items to ensureunimpeded operation of the cutting saw 10.

17. The diver affixes the crane block with slings and shackles to theitem 11 being cut to provide safe holding of the work piece 11′ duringand after cutting. This step also provides lifting tension on the itemto open the cut and aid in the cutting process.

18. The diver returns to a dive bell or to surface prior to initiatingsaw operation.

19. Once instructed to commence cutting by the Dive Supervisor, thehydraulic power unit is started and adjusted for the appropriatepressure and flow rate.

20. The observation camera 81 and light is turned on to monitor the cut.All cutting is recorded on digital video disk for later assessment.

21. The hydraulic power unit is engaged providing pressure to thesystem. The operator having verified all parameters starts the cuttingmachine with the control panel 113.

22. Once a free-spinning drive motor 40 baseline pressure is reached,the diamond wire saw drive motor 40 pressure is monitored for increasedpressure indicating that the diamond wire 16 is cutting.

23. An optimum increased pressure on the cutting wire 16 drive motor 40is approximately 100-300 psi and may be adjusted by incremental movementof the rack and pinion axial wire feed mechanism 20/21.

24. Pressure is monitored throughout the cut. Increased pressure spikescan indicate movement in the target 11 being cut giving the operator 116an indication of pinching of the diamond wire 16 or a complete drop inpressure, indicating a broken wire 16 or that the cut is complete.Visual indications are provided through the camera 81 and lightmonitoring system if water clarity allows.

25. If the cut is not complete, a new diamond cutting wire 16′ is placedon the 10″ idler pulleys 27-30 and tensioned manually by the diver 118with verbal instruction from a Technician via the Dive Supervisor.

26. All hydraulics are disengaged via the control panel 113 once the cutis complete, or in the event that there is a diamond wire 16 breakage.

27. Once the cut is complete, the vessel 37 crane operator moves theextracted cut piece 11′ to the sea floor or returns the piece to thework deck for offloading at a later time.

28. Following a diver survey of the area to ensure no damage to outlyingstructures or equipment has occurred; the vessel crane 37 block islowered to the diver and reattached to the diamond wire saw 10 via thesupplied three part sling.

29. The diver 118 removes the manual chain clamping system 17 and givesverbal guidance to the crane operator for returning the diamond wire saw10 to surface.

30. Once the cutting saw 10 is on the vessel 35 work deck, all hydraulichoses from the hose reel to the saw are disconnected.

31. The cutting saw 10 is thoroughly rinsed with a freshwater solutionand all moving components are lubricated.

32. Cutting saw 10 is maintained on standby until further use is needed.

33. All video footage recorded is reviewed for analysis and improvement.

34. A cutting report can be provided to the customer which can includethe video footage.

Using Cutting Wire Resistance to Determine Advancement of Cutting Wire

In one embodiment the operator 116 of the saw device can be above waterand the cutting saw 10 be below water. In one embodiment the operatorcan use the resistance on the cutting wire 16 to determine when toadvance the cutting wire 16 of the cutting saw 10. In one embodiment theresistance on the cutting wire 16 can be relatively determined based onthe back pressure (e.g., hydraulic back pressure) to the driving motor40 for the cutting wire 16. In one embodiment the cutting processincludes the step of advancing the cutting wire 16 a short distance, andwatching the resistance on the cutting wire 16 increase and then overtime decrease (as the cut on the target 11 is made), and after notingthe decrease in wire 16 resistance, again advancing the cutting wire 16and watching the resistance on the cutting 16 wire again increase. Inone embodiment these two steps of advancing the cutting wire 16 a shortdistance, and watching the resistance on the cutting wire 16 firstincrease and then decrease before again advancing the cutting wire 16are repeated a plurality of times until the cut is made through thetarget 11.

Replacement of Cutting Wire and Alignment Wheels Underwater

In one embodiment the wire 16 can be replaced while the cutting saw 10is underwater, such as during the middle of a cut and without moving thecutting saw 10 above water (e.g., see FIGS. 22 and 23).

In one embodiment while underwater after a first cutting wire 16 hasbroken a second cutting wire 16′ can be placed on the saw device 10 andproperly tensioning without having to first return the saw device 10 tothe surface (e.g., see FIGS. 22 and 23). In one embodiment the axialfeed wire tensioning system 32 can be used to properly tension thecutting wire 16 while the saw device 10 remains underwater (FIG. 22).

In one embodiment one or more of the alignment wheels or sheaves 27-30and 32 can be replaced while the saw device 10 is underwater, such asduring the middle of a cut and without moving the saw device 10 abovewater.

Using Both a Push and a Pull Types of Cuts on a Single Cut

In one embodiment the method includes the step of:

(a) starting a cut with a pushing (or pulling) type cut;

(b) before the cut is completed, stopping the cutting wire 16 and atleast partially removing the cutting wire 16 from the alignment wheelsor sheaves 27-30;

(c) moving the saw device 10 into a different pulling (or pushing) typecut position but without bringing the cutting saw 10 above;

(d) placing cutting wire 16 on the alignment wheels or sheaves 27-30;and

(e) completing the remaining portion of the cut in the other type ofcutting mode.

In one embodiment step “c” is completed without repositioning the clamp17 holding the cutting saw 10 on the target 11.

In one embodiment step “c” is performed by moving the cutting frame 23to a substantially extended position. In one embodiment the cuttingframe 23 is moved to a completely extended position.

In one embodiment step “c” is performed by moving the cutting frame 23to a substantially retracted position. In one embodiment the cuttingframe 23 is moved to a completely retracted position.

In one embodiment the same cutting wire 16 is used during steps “a” and“e.”

In one embodiment a different cutting wire 16′ is in step “e” as thatcutting wire 16 used in step “a”.

In one embodiment the cutting wire 16 used in step “a” is a loop whichis broken into a wire string with two ends and during step “d” the twoends are reconnected to form a loop.

In one embodiment the cutting wire 16 used in step “a” remains in a loopand is placed around the target 11 being cut before step “d” such as bybeing run down the top 11″ of target 11.

In one embodiment the tensioning mechanism 32 is used to loosen thecutting wire 16 in step “b.”

In one embodiment the tensioning mechanism 32 is used to tension thecutting wire 16 in step “d.”

In one embodiment the method includes the step of:

(a) starting a cut with a pushing (or pulling) type cut;

(b) before the cut is completed, the first cutting wire 16 breaking;

(c) removing the first cutting wire 16 from the alignment wheels orsheaves 27-30;

(d) without bringing the cutting saw 10 above water installing a secondcutting wire 16′ on the alignment wheels or sheaves 27-30; and

(e) completing the remaining portion of the cut with the second cuttingwire 16′.

In one embodiment the tensioning mechanism 32 is used to loosen thefirst cutting wire 16 in step “c.”

In one embodiment the tensioning mechanism is used to tension the secondcutting wire 16′ in step “d.”

In one embodiment the method includes the step of vertically adjustingat least one of the alignment wheels or sheaves (27-30 and/or 32) whilethe cutting saw 10 remains underwater.

The following is a list of Reference numerals which are used in thisapplication.

LIST OF REFERENCE NUMERALS Reference Number Description  10 cuttingapparatus  11 target  12 seabed  13 frame  14 shackle  15 lift cable  16diamond wire  16A cutting point of diamond wire  17 mounting clamp  18cable/chain attachment  19 cable/chain attachment  20 feed shaft  21toothed rack  22 receiver  23 moving portion  24 arm  25 arm  26 openend  27 sheave/roller guide  28 sheave/roller guide  29 sheave/rollerguide  30 sheave/roller guide  31 drive roller  32 tensioner mechanism 33 hydraulic fluid supply  34 hydraulic control unit  35 support vessel 36 water surface  37 crane  38 arrow  39 cut  40 motor drive  41hydraulic line  42 hydraulic line  43 drive belt  44 motor drive  45hydraulic line  46 hydraulic line  47 smaller gear  48 larger gear  49pinion  50 arrow  51 section  52 section  53 shaft  54 tube  55 setscrew  56 arrow  57 arrow  58 arrow  59 arrow  60 transverse section  61sleeve  62 arrow  63 web  64 flange  65 end plate  66 adjustment head 67 plate opening  68 threaded rod  69 nut  70 intervally threadedopening  71 bearing/slide  72 arrow  73 curved arrow  74 roller guide 75 annular grove  76 annular flange/stop  77 arrow  78 set screw  79cable  80 camera mount  81 camera  82 post  83 tube  84 cooling system 85 flow line/header  86 nozzle  87 water jet  88 water supply conduit 89 tee fitting  90 arrow  92 light  93 arrow  94 arrow  95 arrow 100hydraulic clamp 101 receiver 102 opening 103 body 104 hinge 105 pivotingarm 106 cylinder 107 pushrod 108 pinned connection 109 arrow 110floatation material 111 bolted connection 112 pinned connection 113control panel 114 instrument 115 control valve/lever 116 operator 117monitor 118 diver 119 wrench 120 lift line 121 wire rope body 122abrasive member

All measurements disclosed herein are at standard temperature andpressure, at sea level on Earth, unless indicated otherwise. Allmaterials used or intended to be used in a human being arebiocompatible, unless indicated otherwise.

The foregoing embodiments are presented by way of example only; thescope of the present invention is to be limited only by the followingclaims.

The invention claimed is:
 1. A wire saw apparatus comprising: a) a framehaving first and second sections configured to attach the first sectionto a target that is to be cut and a moving portion operatively connectedto the frame; b) an elongated beam mounted to the first section of theframe and extending away from the first section and target; c) themoving portion including a pair of arms disposed on opposing sides ofthe beam, an open end positioned near the first section and a transversebar that connects the arms opposite the open end; d) the moving portionhaving a powered driver operably connected to the beam which drivereffects non-rotational movement of the moving portion of the frame alongthe beam; e) a plurality of roller guides on the moving portion of theframe including at least one roller guide mounted at the free end ofeach arm; f) a drive roller on the moving portion, the drive rollerbeing rotatable by a powered motor drive; and g) a diamond wire woundupon the drive roller and guide rollers so that when the drive roller isrotated, the diamond wire travels around the moving portion and from oneroller to another roller.
 2. The wire saw apparatus of claim 1, whereinthe powered driver travels with the moving portion.
 3. The wire sawapparatus of claim 1, further comprising a tensioning mechanism thatenables adjustment of the tension of the diamond wire.
 4. The wire sawapparatus of claim 1, wherein the diamond wire travels at a speed ofbetween about 20 and 30 feet per second.
 5. The wire saw apparatus ofclaim 1, wherein at least one of the rollers is marked with differentpatterns so that rotation of the rollers is visible even via underwatercamera and remote monitor.
 6. The wire saw apparatus of claim 1, whereinthe arm free ends are connected with a section of wire that cuts throughthe target as the moving portion of the frame travels along the beam andtowards the first section.
 7. The wire saw apparatus of claim 1, whereinthe guide rollers on the arm free ends are connected with a section ofwire that extends across the open end of the moving portion.
 8. The wiresaw apparatus of claim 1, wherein the moving portion carries a cameraand light mount.
 9. The wire saw apparatus of claim 1, wherein the guiderollers are removably attached to the moving portion of the frame. 10.The wire saw apparatus of claim 1, wherein rollers and wire define acutting plane and the linear beam includes a toothed rack and is belowthe cutting plane and a drive motor is operably connected to the toothedrack and also positioned below the cutting plane.
 11. The wire sawapparatus of claim 1, wherein the arms are spaced apart a distance thatdefines the maximum thickness of a target that can be cut.
 12. The wiresaw apparatus of claim 1, wherein the arm free ends and transverse barare spaced apart a distance that defines the maximum thickness of atarget that can be cut.
 13. A wire saw apparatus comprising: a) a framehaving first and second sections configured to attach to a target thatis to be cut; b) an elongated beam mounted to the first section andextending away from the first section and target; c) a moving framemounted on the elongated beam and being movable along the beam, theframe including a pair of arms disposed on opposing sides of the beam,an open end positioned near the clamp and a transverse bar that connectsthe arms opposite the open end; d) a motor operably connected to thebeam which motor effects non-rotational movement of the moving framealong the beam; e) a plurality of roller guides on the moving portion ofthe frame including at least one roller guide mounted at the free end ofeach arm; f) a drive roller on the moving portion, the drive rollerbeing rotatable by a second motor drive; g) a diamond wire wound uponthe drive roller and guide rollers so that when the drive roller isrotated with the second motor drive, the diamond wire travels around themoving portion and from one roller to another roller.
 14. The wire sawapparatus of claim 13, wherein the drive roller has a diameter that ismore than two times any of the guide rollers.
 15. The wire saw apparatusof claim 13, wherein the diamond wire travels at a speed of betweenabout 20 and 30 feet per second.
 16. A method of cutting an underwatertarget, comprising the steps of: a) lowering a cutting apparatus to aposition that is next to an underwater target to be cut, the targethaving a longitudinal axis; b) attaching the cutting apparatus to thetarget having first and second sections; c) wherein in step “b” thecutting apparatus includes a frame that the first section configured toattach to a target that is to be cut and a moving portion mounting tothe first section for movement relative to the first section, a beammounted to the first section and extending away from the clamp andtarget, the moving portion includes a pair of arms disposed on opposingsides of the beam and an open end positioned near the first section anda transverse section that connects the arms opposite the open end andwherein a diamond wire is supported for travel upon the frame, the wireconnected to a plurality of rollers including at least one powered driveroller that moves the wire; d) advancing the moving portion toward thetarget while the diamond wire is traveling upon the rollers; and e)wherein in step “d” a driver engages the beam, which engagement causesthe advancement of the moving portion linearly in a direction generallyperpendicular to the longitudinal axis of the target.
 17. The method ofclaim 16, wherein the cutting mechanism is operated remotely from avessel using a control panel.
 18. The method of claim 17, wherein remoteoperation includes monitoring the cutting with an underwater camera thattransmits a signal to a monitor on the vessel.